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Cable Guide: M27500 Specification - NEMA WC 27500 2012 Part Anatomy

The M27500 specification covers the requirements for special purpose and power cables. Commonly used in avionics, aerospace, military, and airframe applications, these constructions are offered in shielded and unshielded cables and are composed of specific conductor sizes, insulation types, number of conductors, shielding material and jacket compounds. Ranging from 1 to 15 conductors, the part number is a combination of digits and letters (not to exceed 16) which help identify the exact components of each cable.

 

While the mil-spec has been replaced with the NEMA WC 27500 cable specification, industry professionals still refer to the spec as M27500. This particular cable is one of the only products where you can determine the construction and components just by evaluating the part number.
So let’s begin to break down the M27500 cable. M27500-20RC2S06 is one example of a part number on this specification:

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A. You can click the corresponding inner conductor on the M27500 cable page and choose your cable type from our product grid.

 

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Click on each segment to receive information about all variations this segment can have.

 

 

 

M27500
 

-

Color Coding and Shield Coverage

20

Conductor Size
 

RC

Base Wire Specification
 

2

Number of Conductors

S

Shield Type
 

06

Outer Jacket Material

Identifying the Specification – Every part number will begin with M27500 because this is the specification call out. 
Color Code – The identification method is designated by a single character that denotes the color coding, identification sequence, and the amount of shield coverage.  Our example indicates a “-” color coding, which requires one white conductor and one white conductor with a blue stripe all shielded with 85 percent coverage.
 
Conductor Size – The basic wire size of the inner conductors will be identified. In this particular part number, the cable is composed of 20 gauge inners.
 
Cable Designators (Basic Wire specifications) – A one or two letter symbol will be used to designate the specification, type, and class of the inner conductors. In the above part , the designator is “RC” meaning the cables inners are M22759/11.
 
Number of Conductors Per Cable-This number defines how many inner conductors the cable will include. Depending on your shield and gauge sizes, the cables will have 1 to 15 conductors. Our example part would be composed of two inner conductors of M22759/11.
 
Shield style and material - The shield style and material of the overall shields will be designated by a single letter. Above we have an “S” shield which signifies a round silver-coated copper shielding.
 
Jacket material and temperature rating- The type of jacket is determined by a two digit number at the end of the product call out. Depending on the call out, the cable can be a single or double jacket. Single jacketed cables only have an outer jacket, but when double jacketed there is a jacket between a double shield and a jacket covering the outer shield. Since our example states an “06” jacket, we would have a single extruded taped PTFE jacket.
 
Breaking down part numbers can help you gain knowledge and understanding about the products you are purchasing and using daily. WireMasters is here to make your job easier!  By using our reference sheets, you can reassure yourself on selecting the appropriate cable that best fits your application. By evaluating the M27500 part, we can look at all the cables characteristics without visually seeing the product. Below is a downloadable PDF chart to help you break down the M27500 specification.

 

WIREMASTERS M27500 PDF CHARTS

WireMasters carries a variety of these cables in stock.  We are also on the QPL, which allows us to build U00 cables in-house! You may use these charts and PDF’s as a reference, but also feel free to contact our experienced sales staff for help locating the correct products and solutions for your application. Holding large stock quantities of these cables, we can ship your cable out the door the same day you place your order.  If we don’t have the cable you are looking for, we can create a custom cable and work with our manufacturing partners to have it built just for you!

Color Code

The identification method is designated by a single character that denotes the color coding, identification sequence, and the amount of shield coverage. Our example indicates a “-” color coding, which requires one white conductor and one white conductor with a blue stripe all shielded with 85 percent coverage.

Table A: Color Identification Method for Wire and Shield Coverage +

Shield Coverage

MIL-DTL-27500
Terminology

Color Identification Method

85%

90%
- C Preferred method Table A-1 Colored Stripes on White Wire-Stripe Color per Table A-1
A D Optional Method A Table A-1 Solid Color Wires-Colors per Table A-1
B E Optional Method B Table A-3 Band Marking (wire number) per Table A-4 on Solid Colors (by AWG) per Table A-3
F H Preferred Method Table A-2 Colored Stripes on White Wire-Stripe Color per Table A-2
G J Optional Method A Table A-2 Solid Color Wires per Table A-2
K M Optional Method C Table A-3 Number Marking on Solid Color Wires (by AWG) per Table A-3
L N Optional Method D Number Marking on White Wires
P R Optional Method B Table A-4 Band Marks per Table A-4 on Colored Stripes (by AWG) per Table A-3
S T Optional Method B Table A-4 Band Marks per Table A-4 on White Wires
U V -- For Color Codes Specified by the Procuring Activity
Table A-1: Color Coding +

Preferred Method - Colors are stripes on white insulation (wire #1 has no stripe).


Optional Method A - Colors are solid insulation color. Wires 11-15 have a lighter base color stripe.


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15
White Blue Orange Green Red Black Yellow Violet Gray Brown Blue/Blue Orange/Orange Green/Green Red/Red Black/Black

Conductor Size


The basic wire size of the inner conductors will be identified. In this particular part number, the cable is composed of 20 gauge inners.

Cable Designators (Basic Wire specifications)

A one or two letter symbol will be used to designate the specification, type, and class of the inner conductors. In the above part , the designator is “RC” meaning the cables inners are M22759/11.

Table B: Base Wire Specification
By Symbol Sequence By Specification Sequence
A SAE AS5086/1 NK SAE AS81381/21 SAE AS22759/1 EA SAE AS22759/85 WH
AA SAE AS5086/5 NL SAE AS81381/22 SAE AS22759/2 E SAE AS22759/86 WJ
AB SAE AS5086/6 P SAE AS5086/4 SAE AS22759/3 RA SAE AS22759/87 WK
AD SAE AS5086/7 RA SAE AS22759/3 SAE AS22759/4 RB SAE AS22759/88 WL
B SAE AS5086/2 RB SAE AS22759/4 SAE AS22759/5 VA SAE AS22759/89 WM
C SAE AS5086/3 RC SAE AS22759/11 SAE AS22759/6 WA SAE AS22759/90 WN
CA SAE AS22759/13 RE SAE AS22759/12 SAE AS22759/7 SA SAE AS22759/91 WP
CB SAE AS22759/14 SA SAE AS22759/7 SAE AS22759/8 TA SAE AS22759/92 WR
CC SAE AS22759/15 SB SAE AS22759/32 SAE AS22759/9 LE SAE AS25038/1 JA
E SAE AS22759/2 SC SAE AS22759/33 SAE AS22759/10 LH SAE AS25038/3 JF
EA SAE AS22759/1 SD SAE AS22759/34 SAE AS22759/11 RC SAE AS5086/1 A
F SAE AS8777, MS 27110 SE SAE AS22759/35 SAE AS22759/12 RE SAE AS5086/2 B
H SAE AS8777, MS 25471 SM SAE AS22759/41 SAE AS22759/13 CA SAE AS5086/3 C
JA SAE AS25038/1 SN SAE AS22759/42 SAE AS22759/14 CB SAE AS5086/4 P
JB SAE AS22759/28 SP SAE AS22759/43 SAE AS22759/15 CC SAE AS5086/5 AA
JC SAE AS22759/29 SR SAE AS22759/44 SAE AS22759/16 TE SAE AS5086/6 AB
JD SAE AS22759/30 SS SAE AS22759/45 SAE AS22759/17 TF SAE AS5086/7 AD
JE SAE AS22759/31 ST SAE AS22759/46 SAE AS22759/18 TG SAE AS81044/5 MD
JF SAE AS25038/3 TA SAE AS22759/8 SAE AS22759/19 TH SAE AS81044/6 ME
LE SAE AS22759/9 TE SAE AS22759/16 SAE AS22759/20 TK SAE AS81044/7 MF
LH SAE AS22759/10 TF SAE AS22759/17 SAE AS22759/21 TL SAE AS81044/8 MG
MD SAE AS81044/5 TG SAE AS22759/18 SAE AS22759/22 TM SAE AS81044/9 MH
ME SAE AS81044/6 TH SAE AS22759/19 SAE AS22759/23 TN SAE AS81044/10 MJ
MF SAE AS81044/7 TK SAE AS22759/20 SAE AS22759/28 JB SAE AS81044/11 MK
MG SAE AS81044/8 TL SAE AS22759/21 SAE AS22759/29 JC SAE AS81044/12 ML
MH SAE AS81044/9 TM SAE AS22759/22 SAE AS22759/30 JD SAE AS81044/13 MM
MJ SAE AS81044/10 TN SAE AS22759/23 SAE AS22759/31 JE SAE AS81381/7 MR
MK SAE AS81044/11 VA SAE AS22759/5 SAE AS22759/32 SB SAE AS81381/8 MS
ML SAE AS81044/12 WA SAE AS22759/6 SAE AS22759/33 SC SAE AS81381/9 MT
MM SAE AS81044/13 WB SAE AS22759/80 SAE AS22759/34 SD SAE AS81381/10 MV
MR SAE AS81381/7 WC SAE AS22759/81 SAE AS22759/35 SE SAE AS81381/11 MW
MS SAE AS81381/8 WE SAE AS22759/82 SAE AS22759/41 SM SAE AS81381/12 MY
MT SAE AS81381/9 WF SAE AS22759/83 SAE AS22759/42 SN SAE AS81381/13 NA
MV SAE AS81381/10 WG SAE AS22759/84 SAE AS22759/43 SP SAE AS81381/14 NB
MW SAE AS81381/11 WH SAE AS22759/85 SAE AS22759/44 SR SAE AS81381/17 NE
MY SAE AS81381/12 WJ SAE AS22759/86 SAE AS22759/45 SS SAE AS81381/18 NF
NA SAE AS81381/13 WK SAE AS22759/87 SAE AS22759/46 ST SAE AS81381/19 NG
NB SAE AS81381/14 WL SAE AS22759/88 SAE AS22759/80 WB SAE AS81381/20 NH
NE SAE AS81381/17 WM SAE AS22759/89 SAE AS22759/81 WC SAE AS81381/21 NK
NF SAE AS81381/18 WN SAE AS22759/90 SAE AS22759/82 WE SAE AS81381/22 NL
NG SAE AS81381/19 WP SAE AS22759/91 SAE AS22759/83 WF SAE AS8777, MS 25471 H
NH SAE AS81381/20 WR SAE AS22759/92 SAE AS22759/84 WG SAE AS8777, MS 27110 F

Number of Conductors Per Cable

This number defines how many inner conductors the cable will include. Depending on your shield and gauge sizearia-modal="true" aria-value="0"s, the cables will have 1 to 15 conductors. Our example part would be composed of two inner conductors of M22759/11.

Shield style and material

The shield style and material of the overall shields will be designated by a single letter. Above we have an “S” shield which signifies a round silver-coated copper shielding.

Table C: Shield Type +
SINGLE SHIELD DOUBLE SHIELD SHIELD MATERIAL MAXIMUM TEMP
U -- No Shield --
T V TPC Round 150°C
S W SPC Round 200°C
N Y NPC Round 260°C
F Z Stainless Steel 400°C
C R NPC 27% Round 400°C
M K SPC Alloy Round 200°C
P L NPC Alloy Round 260°C
G A SPC Flat 200°C
H B SP High Strength Copper Alloy Flat 200°C
* # NPC Flat 260°C
J D TPC Flat 150°C
E X NP High Strength Copper Alloy Flat 260°C
I Q Nickel-Chromium Alloy Flat 400°C

Jacket material and temperature rating

The type of jacket is determined by a two digit number at the end of the product call out. Depending on the call out, the cable can be a single or double jacket. Single jacketed cables only have an outer jacket, but when double jacketed there is a jacket between a double shield and a jacket covering the outer shield. Since our example states an “06” jacket, we would have a single extruded taped PTFE jacket.

Table D: Jacket Type +
SINGLE SHIELD DOUBLE SHIELD JACKET MATERIAL MAXIMUM TEMP
00 00 No Jacket ----
01 51 Extruded White PVC 90°C
02 52 Extruded Clear Polyamide 105°C
03 53 White Polyamide Braid Over Polyester Tape 105°C
04 54 Polyester Braid over Polyester Tape 150°C
05 55 Extruded Clear FEP 200°C
06 56 Extruded or Taped White PTFE 260°C
07 57 White Glass Braid PTFE Over PTFE Tape 260°C
08 58 Cross linked White Extruded PVDF 150°C
09 59 Extruded White FEP 200°C
10 60 Extruded Clear PVDF 125°C
11 61 Polyimide over FEP wrapped Polyimide tape 200°C
12 62 Polyimide over FEP wrapped Polyimide tape 200°C
14 64 Extruded White ETFE 150°C
15 65 Extruded Clear ETFE 150°C
16 66 PTFE Tape Over Polyamide Braid 200°C
17 67 Extruded White ECTFE 150°C
18 68 Extruded Clear ECTFE 150°C
20 70 Extruded White PFA 260°C
21 71 Extruded Clear PFA 260°C
22 72 Polyimide over FEP wrapped Polyimide tape 200°C
23 73 Extruded, White, Modified XLETFE 200°C
24 74 White Polymide PTFE Tape, FEP 260°C